Method of making forms.



, IVI. D. PHELAN.

METHOD of MAKING foams. APPLICATION FILED MAY I5. 19H.

Imm@ Jaw, 1919.

WVM/75H.

MERTON I D. y3PT-IIElllulilllal', 0F BOSTON, MASSACHUSETTS, ASSIGNOR. BYMESNE ASSIGN- MENTS, TO UNITEJD SHOE MACHINERY CORPORATION, OF PATERSON,NEW JERSEY, .A CORPORATION OF NEW ElEtStTS'.`

METHOD OF MAKING FORMS.

Specification of Letters Patent.

Patented dan.. t, titille.

Application led May 15, 1917. Serial No. 168,839.

of which the followingdescription, in cony nection with the accompanyingdrawings, is

a specification, like reference characters on the dra-wings indicating1like parts in the sev eral figures.

rllhis invention relates to a method of uniting two metals or alloys ofdifferent melting1 points and, in order to promote brevity, will bedescribed as embodied Vin a method oi' makingbrass-faced iron terms forluse in boot and shoe sole-molding machines.

ln the manufacture of certain types of boots and shoes it is customaryto shape the soles ot the shoes by subjecting' them while wet to a heavypressure between suitably shaped forms. When these forms are made ofiron and are allowedto come into direct cont-act with the soles a veryobjectionable black discoloration is produced due probably to theformation oi' iron tannate by the action ot a solution of tannic acid inthe leather upon the iron ot the forms. lt would, ot' course, bepossible to obviate this undesirable result by making the 'forms ot someother metal than iron, for example of brass, but the expense involved isalmost if not quite prohibitive. The object of the present method is toproduce a form the body of whih is iron or other inexpensive metal oralloy but the operative portion of which is brass or other suitablealloy orI metal, the brass portion or facing; being oi: su-cientthickness and attached with suftcient strength to the iron to permit itto stand prolonged and severeuse.

ln the illustrative method a brass plate is placed in a mold and thenmolten iron 1s introduced into the mold whereby the brass 1s melted andremains molten after` the iron has solidified. The plate is not 'flatbut has high and low portions; and as ay consequence ot this and of :theshrinkage which takes place as the iron solidities, the brass tends torun down leaving one or more localities thinner than others. ln oneotite aspects the invent-ion comprises a method ot making a compositearticle of two materials having dierent melting points which consiststlOIlll illllOlUlt of the same material.

in placing` in a mold a piece ot' the material having the lower meltingpoint. pouring into contact with it molten material having the highermeltingpoint whereby the material having;` the lower meltinir'point ismelted, and then pouring into the molten material having the lowermelting' point an addi- In the illustrative method an additional amountof molten brass is poured into the molten brass after the iron hassolidified.

In another of its aspects the invention comprises a method such as thatdescribed above in which the piece or plate of the material having thelower melting point is .suspended in the upper part ot the mold and themolten material having the higher melting point is poured in frombeneath.

These and other aspects of the invention will be set t'orth inconnection with an illus trative apparatus by which the method may bepractised.

y Referring now to the accompanying` drawings;-

ligure 1 shows a brass plate supported above a pair oi' Bunsen burnersas it appears aiiter having;` received its coating;

Fig'. 2 shows an open molding box with the brass plate suspended in theupper por-v tion of the mold;

Fig. 3 is a section in detail showing more particularly the manner inwhich the plate is suspended;

Fig. l is a vertical longitudinal section through the molding` box afterthe brass and iron have solidified.

ln carrying out the method of the present invention, a. brass plate 5 isfirst provided having the desired shape except that two ears 7 projectfrom its sides and are pro vided with threaded holes 9 to receive thethreaded ends of rods ll. These rods have eyes at their upper endsthrough which eX- tends a long rod 13 the ends ot which rest upon wedges15 laid upon the upper part of the molding box. By forcing the wedgesbeneath the long,- rod 13 the brass plate may be held firmly in. placeas shown in Figs. and 3.

Before, however, it is suspended or :tastened in place as has beendescribed, it receives the following treatment. First it is cleaned inany suitable manner, as :tor instance by being batted. lt is then laidon 'The plate is then cooled,

a. suitable support such as the rods 19 and brought to and maintained atthe desired temperature by any suitable heating apparatus such as theBunsen burners 21. While the plate is hot it is coated with solder onthe side against which the molten iron will rise in the moldgthen brasschips are dropped upon the pasty solder, then a little' muriatic acid issprinkled over the chips and solder, and finally a coating of borax isdusted over the whole surface. the solder acting to hold the chips andborax in place on the .plate after the plate has been inverted andsuspended from the rod 13 in the upper part of the mold as shown in Fig.2, the plate being embedded in and flush with the surface of the moldingsand except at its rear portion. At the rear of the platethat is at theportion which is adjacent to the heel portion in the finished form-a`hollow is formed in the sand as indicated by the line 23 so that theheel portion ofthe finished form will have anviron surface. Thisparticular sort of form is, however, immaterial so far as the presen-tinvention is concerned.

In the lower half of the molding box is formed the lower portion of themold 25 into which the molten iron is to be poured. This lower portionhas a core 27 extending into it to provide a slot to receive a bolt bywhich the form when finished may be fastened to a support in use. Thiscore, however, and the particular shape given to the heel portion of theform by so far as the present invention is concerned and may be changedor dispensed with as may be desired. Leading out of the mold 25 are twochannels 28 over parts of which the ears 7 of the plate 5 lie when themolding box has been closed (see Fig. 3) and How gates or sprues 29 leadupwardly from these channels. The ingaite through which the molten ironenters the mold is indicated at 31. The rods 11 extend through sprues orgates 33, 35 in the upper half of the mold of which one, for example 33,serves, as will presently be described, as an ingate and the other as aHow gate.

In practising the method the upper and lower parts of the molding boxare fastened together in the usual manner after the plate 5 has beencoated as described and fixed in place inftheV upper portion of themold. Molten iron is then poured down the ingate 31, flows into thebottom of the mold and rises in the mold and in/the sprues 29. The heatof the iron melts the brass plate and maintains the brass in a moltencondition for some time after Ytheiron has solidified. The molten brassunder these circumstances and owing to the shrinkage of the iron tendsto flow down toward the ends of the mold, for example to the level ofthe broken. line A-A in Flg. 4 and it becomes necessary to 1t, isimmaterial supply more brass to fill the space above this line. To thisend the rods 11 are lifted out, and molten brass is poured down thesprue 33 and rises in the sprue 35. It will be understood that thelocation of the line A-A in the drawing is purely arbitrary and has beenused merely to indicate in a general waywhat would be the effect if noextra brass were added. The bond which is produced by this methodbetween the brass and iron possesses great strength, the metalsapparently mingling more or less in their molten states and thus to anextent becoming embedded one in the other.

Having thus described my invention, I claim as new and desire to secureby Letters Patent:

1. The method of making a form having an iron base and a brass workingsurface which consists in placing a brass plate in a mold, pouring inmolten iron whereby the brass is melted and remains molten after theiron adjacent to it has solidified, and then pouring into themoltenbrass an additional amount of the same material.

2. The method of making av form having an iron base and a brass workingsurface which consists in suspending a brass plate in the upper part ofa mold, pouring in molten iron from beneath whereby the brass is meltedand remains molten after the upper portion of the iron has solidified,and then pouring in from the top a small amount of molten brass.

3. The method of making a` form having an iron base and a brass workingsurface which consists in applying to one face of a brass plate a`coating comprising solder, small particles of a. metal having a lowermelting point than that ol iron and a flux, vsuspending the plate in theupper part of a mold with the coated face downward, and pouring inmolten iron from beneath.

4. The method of making a form having an iron base and a brass workingsurface wlifich consists in applying to one face of a brass plate a.coat-ing comprising solder, small particles of a` metal, having a lower.melting point than that of iron and a iiux, suspending the plate in theupper part of a mold with the coated face downward. pouring in molteniron from beneath, and then after the bra-ss has melted pouring in fromthe top a. small amount of molten brass.

5. The method of uniting a plate of brass to a base of iron whichconsists in applying to one face of the plate a` coating comprisingsolder, brass chips and a flux, suspending the plate in the upper partof a. mold with the coated face downward, and pouring the iron in frombeneath.

6. The method of uniting a plate of brass to a. base of iron whichconsists in applying to one face of the plate a coating comprisingsolder, brass chips and a flux, suspending the plate in the upper partof a mold with the coated tace downv 1ard, pouring the iron in frombeneath, and then after the brass has melted pouring in from the top asmall amount of molten brass.

7. The method ot' making a iorm having an iron base and a brass workingsurface which consists in heating a b ass plate, applying to the platewhile hot a coating comprising solder, brass chips and a flux, allowingthe plate to cool, suspending the plate-in a mold with the coated tacedownward, and

pouring in molten iron from beneath.

8. The method of making a form having an iron base and a brass workingsurface which consists in heating a brass plate, applying to the platewhile hot a coating comprising solder, brass chips and a iiux, allowingthe plate to cool, suspending the plate in a mold with the coated facedownward, pouring in molten iron from beneath, and after the brass hasmelted, pouring in from the top a small amount of molten brass.

9. The method of making a metallic form comprising a base and a workingsurface which consists in placing in a mold a plate of the materialhaving the lower melting point, pouring in molten material of the highermelting point whereby the material of thelower melting point is melted,and re- .ma-ins molten after the material of the higher melting hassolidified, and the-n'pouring into the molten material of the lowermelting point an additional amount of the same material. v

l0. The method of making a form having an iron base and a working faceof an alloy of lower melting point than iron which con-v sists insuspending a plate of the alloy in the upper part of a mold, pouring inmolten iron from beneath whereby the alloy is melted and remains moltenat'ter the iron has solidified, and then pouring in from the top a smallamount of molten alloy.

l1. The method ot' making a torni of two materials having differentmelting points which consists in applying to one face of a plate ot' thematerial having the lower melting point., a coating of solder, placingthe plate in a mold with the coated face exposed, and pouring in moltenmaterial of the higher melting point.

12. The method otl making a form ot' two materials having differentmelting points which consists in applying to one face of a plate ot' thematerial having the lower melt ing point a coating ot' solder, placingthe plate in `a mold with the coated face exposed, pouring in moltenmaterial of the higher meltingpoint whereby the plate is melted andremains molten after the material of the higher melt-ing point hassolidified, and then pouring into the molten material ot' the lowermelting point an additional amount of the same material. Y

13. The method of making a composite article of two materials havingdifferent meltf ing points which consists in placing in a mold a pieceof the material having the lower melting point, pouring upon it moltenmaterial having the higher melting point, and then pouring in molten`material having the lower melting point.

In testimonv whereot` I have signedmy name to this specification.

MERTUN D. PHELAN.

